Temperature Maintaining Shipping Package

ABSTRACT

A package and method of use for packaging temperature sensitive payloads during transport through environments having extreme temperatures. The package includes a segmented, flexible panel containing a plurality of phase change material segments. A pair of such panels may be used, with each panel being separately thermally preconditioned as a function of anticipated ambient temperature during transport. The panels may be formed by retaining phase change material segments between a pair of flexible sheets.

RELATED APPLICATIONS

This applications claims priority from U.S. Provisional PatentApplication No. 60/991,658, filed Nov. 30, 2007, and hereby incorporatedby reference in its entirety.

TECHNICAL FIELD

The present invention is directed to a package, such as used duringtransport, for a temperature sensitive payload and a method of use. Moreparticularly, the present invention relates to a package and method ofuse for shipping temperature sensitive materials via common carrier.

BACKGROUND OF THE INWENTION

Packages incorporating phase change materals for transport oftemperature sensitive payloads are well known. A phase change material(PCM) is a substance with a high heat of fusion which, upon melting andsolidifying at certain temperatures, is capable of storing or releasinglarge amounts of energy. Initially, solid-liquid PCMs perform somewhatlike conventional storage materials: their temperature nrses as theyabsorb heat. Unlike conventional storage materials, however, when suchPCMs reach their phase change temperatures (i.e., melting pointtemperature) they absorb large amounts of heat without a significantrise in temperature. When the ambient temperature around a lquidmaterial falls, the PCM solidifiesv releasing its stored latent heat.Certain PCMs store 5 to 14 times more heat per unit volume thanconventional storage materials such as iron, masonry, or rock.

Transporting temperature sensitive materials through environments havingextreme ambient temperatures in a manner that does not require a powersource or other mechanical device is desirable. Various methods havebeen advanced for this purpose. For example, prior known devices haveemployed phase change materials in liquid form to encase a payload toprotect materials from colder ambient temperatures and phase changematerials in solid form to encase a payload to protect materals fromhotter ambient temperatures.

PCMs can be broadly grouped into two categories: “Organic Compounds”(such as polyethylene glycol) and “Salt-based Products” (such asGlauber's salt). The most commonly used PCMs are salt hydrides, fattyacids and esters, and various paraffins (such as octadecane). Ionicliquids have also been investigated as novel PCMs.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to a package and method of thermallyprotecting a payload with phase change materals and an outer container,wherein the PCM material is provided in segmented panels. In oneembodiment, a payload is surrounded with phase change material containedwithin segmented PCM panels that are wrapped around a payload. A packagein accordance with the present invention may include multiple segmentedpanels of phase change material.

It is particularly desirable to have a storage or shipping containercapable of thermally protecting a payload such as, but not limited to, abottle or bottles of pills. An embodiment of the present inventionrelates includes a package defined by an outer container, such as anenvelope, which contains one or more flexible, segmented PCM panelssurrounding a payload. In one example, the segments are defined bybondings between panel surfaces. Such a bond can be formed via a thermalbonding procedure. One embodiment of the present invention utilizesmultiple panels of generally similar form to define a plurality ofsegmented PCM portions.

The foregoing has outlined rather broadly the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood.Additional features and advantages of the invention will be describedhereinafter which form the subject of the claims of the invention. Itshould be appreciated by those skilled in the art that the conceptionand specific embodiment disclosed may be readily utilized as a basis formodifying or designing other structures for carrying out the samepurposes of the present invention. It should also be realized by thoseskilled in the art that such equivalent constructions do not depart fromthe spirit and scope of the invention as set forth in the appendedclaims. The novel features which are believed to be characteristic ofthe invention, both as to its organization and method of operation,together with further objects and advantages will be better understoodfrom the following description when considered in connection with theaccompanying figures. It is to be expressly understood, however, thateach of the figures is provided for the purpose of illustration anddescription only and is not intended as a definition of the limits ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference isnow made to the following descriptions taken in conjunction with theaccompanying drawing, in which:

FIG. 1 is an view of a package assembly in a disassembled state inaccordance with the present invention.

FIG. 2 is a view of a portion of the package assembly of FIG. 1.

FIG. 3 is a cross-sectional view of the package assembly taken alonglines A-A of FIG. 1.

FIG. 4 is a cross-sectional view of the package assembly taken alonglines B-B of FIG. 2.

FIG. 5 is a view of a portion of the package assembly of FIG. 1 duringan assembly process.

FIG. 6 is a view of the package assembly of FIG. 5 during the assemblyprocess.

FIG. 7 is a view of the package assembly of FIG. 1 in a ready-to-shipstate.

FIGS. 8-11 are views of another embodiment of a package assembly inaccordance with the present invention.

FIGS. 12-14 are graphs of test data collected during actual shipments ofpackages in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIG. 1, there is shown one embodiment of a package 10in a disassembled state. Package 10 includes outer container 11 and apair of phase change material (PCM) panels 13. A payload is provided,which in this example, is a pair of bottles 16. As disclosedhereinafter, payload 16 is contained within rolled PCM panels 13 andcontainer 11 upon assembly.

In the illustrated embodiment, container 11 is an envelope. Container 11may be insulated or uninsulated. In other embodiments, container 11 mayassume alternative forms, including, but not limited to, nonrectangularforms. Container 11 may be of plastic or polymer material, corrugatedpaper or corrugated plastic or other suitable material.

PCM panels 13 may assume different shapes or forms in alternativeembodiments. Panels 13 contain a plurality of PCM segments 18. In theillustrated embodiments of FIGS. 1-11, a pair of flexible, segmented PCMpanels 13 are employed in package 10. In the embodiment of FIGS. 1-7,panels 13 are segmented in two generally orthogonal directions, forsimplicity sake referred to herein as “horizontal” and “vertical”directions. In comparison, the embodiment of FIGS. 8-11 utilize panels13 which are segmented in a single directions, e.g., vertical. As shownin FIGS. 1 and 2, panels 13 of are segmented in both horizontal andvertical directions.

Panels 13 are defined by a plurality of separated PCM-containingsegments 18. These segments 18 are separated by linear voids 19. Voids19 may be defined during a thermal bonding manufacturing process. Forexample, the voids 19 and cavity forming segments 18 may be formed froma pair of thermoplastic sheet material brought together during a thermalbonding/filling process. Voids 19 may be continuous, that is to say eachsegment 18 is separated from each other and PCM is prevented fromflowing from one segment 18 to an adjacent segment 18. In anotherembodiment, voids 19 may be non-continuous and PCM is able to flow fromone segment into another segment 18 when an external force is supplied.In short, the interior volumes of segments 18 may be either separated orprovided in fluid communication with each other.

FIGS. 3 and 4 represent cross-sectional views taken along lines A-A andB-B in FIGS. 1 and 2, respectively. Each segment 18 contains a quantityof PCM held between upper and lower films 20, 21. In one embodiment,segments 18 are defined between pairs of void regions 19 wherein filmlayers 20, 21 are brought together during a sealing/filling process. PCMis held within volumes contained between film layers 20, 21. The size ofsegments 18 could depend on a variety considerations including, but notlimited to, temperature constraints of payload and/or anticipatedambient temperature during shipping, size of payload, size or weightlimitations of shipper, etc. It should be appreciated that alternativesegment 18 designs could also be utilized depending, for example, on thegeometry of the payload, thermal constraints, etc. As suggested by FIG.5, slits or perforations may be formed in upper and/or lower segmentportions such as indicated by numeral 29. Such slits or perforations 29may be beneficial during a panel 13 rolling process as further disclosedherein. Slits or perforations 29 are shown in phantom line to indicatethat for other embodiments of panel 13, slits or perforations 29 may ormay not be present.

FIGS. 2 and 4-6 depict the process of assembling package 10. In FIG. 2,payload 16 has been placed upon upper film surface 20 of segmented panel13. Prior to assembly, panels 13 have desirably been thermallyconditioned. Assuming the same PCM material is used in the pair ofpanels 13, one the panels may be preconditioned to be solid and theother panel may be preconditioned to be liquid. Panels 13 arepreconditioned depending on the temperature constraints of a givenpackage. In other embodiments, more than two PCM panels 13 could beused.

FIG. 4 depicts rolling one of the PCM panels 13 around payload 16. Nextthe other PCM panel 13 is rolled around the first PCM panel 13. FIG. 5depicts the combination of PCM panels and payload 16 as inserted intocontainer 11. Flap 30 of container 11 is subsequently folded intoadhesive contact with a panel surface. FIG. 7 depicts package 10 asassembled and ready to ship. Package 10 may be adapted to be mailedas-is, or alternatively package 10 or a plurality of packages 10 may becontained in yet another larger package (not shown), such as a box.Container 11 may be adapted to directly receive a label, stamps or otherindicia utilized during the shipping process.

Referring to FIGS. 5 and 6, because payload 16 does not extend to edgesof panel 13, end portions of panels 13 may be folded over to fullyenclose payload 16. In comparison, the panels 13 of a second embodimentas shown in FIGS. 8-11 are not folded over.

FIGS. 8-11 illustrate another embodiment of package 100. FIG. 8 depictsa disassembled package 100 including a pair of flexible, PCM panels 13and container 110. In comparison to package 10 of the first embodiment,PCM panels 13 are defined by a plurality of vertical voids 190. As shownin FIGS. 9 and 10, payload 160 extends substantially across panel 130.When panels 13 are wrapped around payload 160, ends of payload 160 maybe visible as shown in FIG. 11.

The present invention is also directed to a package and method forencasing a payload cavity with flexible, segmented panels 13 containingphase change material. In one example, a water based phase changematerial is combined with another phase change material to providethermal protection for the payload. By properly selecting the phasechange materials, a package can be configured to provide maximum thermalprotection for a temperature sensitive product during delivery.Employing a combination of solid and liquid phase change materials inthe container can provide protection from both hotter and colder ambienttemperatures during delivery, and a beneficial reduction in the amountof certain phase change materials can result.

Embodiments of the present invention may include two or more differentphase change materials. In one embodiment, a water-based phase changematerial is utilized along with a 2^(nd), non-water-based phase changematerial. In one embodiment, a temperature sensitive product isprotected against thermal damage from the water-based phase changematerial by an intermediate phase change material. Depending on thedesired temperature range, a variety of different phase change materialsmay be utilized to keep a temperature sensitive product warm or coldduring shipment through an environment having substantially differenttemperatures than desired. For example, prior to shipment one or both ofthe phase change materials 13 can be preconditioned so that phase changematerial is in liquid form or solid form. Depending on the anticipe matea e eeture profile, the most effective combination of solid and liquidphase change material can be selffecte combination is needed, auxiliaryphase change material in solid, liquid, or solid and liquid phase can beadded to augment the thermal capabilities of the container.

FIGS. 12-14 illustrate test data associated with three test shipments ofa package in accordance with the present invention. Three packages weretransported to either Florida or New York from Minneapolis usingordinary available shippers. Temperature of the payload was monitored aswell as the ambient temperature as felt by the outer container. Data wasmeasured by two temperature sensing/recording devices contained withincontainer. Temperature and time as collected during the tests areprovided in graph form. Each test package maintained the payload withina 5 deg. C. temperature band (25.0-20.0 deg. C.) over at least a two dayperiod while the ambient temperature dipped above or below thetemperature band. Test success for a package was defined by the packagemaintaining the payload within the desired temperature band for at leasttwo days during the transport process.

Selection of the phase change materials may include consideration ofmultiple factors including, but not limited to, the desired protectedtemperature range, anticipated ambient temperatures during shipment,thermal properties of the different phase change materials, thermalproperties of the container and/or insulation panels, and thermalproperties of the temperature sensitive product being shipped. Thedesign and sizing of containers of for the phase change material and theinsulation panels could vary depending on these factors as well.

A temperature maintaining packaging system in accordance with thepresent invention includes an insulated or non-insulated outercontainer, including but not limited to a box or envelope made ofplastic film, metallic foil or other suitable material, a phase changematerial panel or panels consisting of a sealed cavity or cavitieswithin a plastic film or other suitable material that is/arepreconditioned to be solid, liquid, or solid and liquid in varyingpredetermined combinations covering or mostly covering the interior ofthe outer container or envelope, and possibly a secondary phase changematerial sealed within a plastic film or other suitable material havinga single cavity or multiple cavities that is/are preconditioned to besolid, liquid, or solid and liquid in varying predetermined combinationscovering or mostly covering the interior of the first phase changematerial panel or panels all to thermally protect a payload within thecenter of the package.

A temperature maintaining packaging system in accordance with thepresent invention includes an outer rigid or semi-rigid tube or hollowcontainer made of paper, plastic or other suitable material along withsuitable caps for enclosing the package, a suitable insulation such as aplastic foam capable of wrapping around a phase change material panel orpanels and a payload container, a phase change material panel or panelsconsisting of a sealed cavity or cavities within a plastic film or othersuitable material that is/are preconditioned to be solid, liquid, orsolid and liquid in varying predetermined combinations covering ormostly covering the interior of the outer container, and possibly asecondary phase change material sealed within a plastic film or othersuitable material having a single cavity or multiple cavities thatis/are preconditioned to be solid, liquid, or solid and liquid invarying predetermined combinations covering or mostly covering theinterior of the first phase change material panel or panels all tothermally protect a payload within the center of the package.

The temperature maintaining package system in accordance with thepresent invention includes PCM panels wherein the phase change materialsare preconditioned to be solid, liquid, or both solid and liquid.

The invention is directed to a method of preparing, packaging andshipping a container or envelope to thermally protect a payload oftemperature sensitive materials including: wrapping the payload materialto be thermally protected in a phase change material panel with one ormore segments of phase change material conditioned to be solid orliquid; wrapping the payload and initial phase change material panel ina secondary phase change material panel with one or more segments ofphase change material conditioned to be solid or liquid; as needed,wrapping the payload and panels with successive layers of phase changematerial panels as space and temperature protection demands; placing thepayload wrapped with phase change material panels into the outercontainer or envelope; and sealing the payload and phase change materialpanels inside the container and performing any necessary operations tocomplete the package such as but not limited to placing shippinginformation on the package, placing postage and instructions on thepackage, or puncturing a vacuum sealed outer envelope to allow expansionof the insulation material.

Another method of preparing, packaging and shipping a container tothermally protect a payload of temperature sensitive materials includes:wrapping the payload material to be thermally protected in a phasechange material panel with one or more cavities of phase change materialconditioned to be solid or liquid; wrapping the payload and initialphase change material panel in a secondary phase change material panelwith one or more cavities of phase change material conditioned to besolid or liquid; as needed, wrapping the package in successive layers ofphase change material panels as space and temperature protectiondemands; wrapping the payload wrapped with phase change material panelsinside the with suitable insulation such as foam insulation; and sealingthe payload, phase change material panels, and insulation inside thecontainer and performing any necessary operations to complete thepackage such as but not limited to attaching end caps to the container,placing shipping information on the package, or placing postage andinstructions on the package.

The PCM panels may include phase change materials that have beenpreconditioned separately to be solid and liquid by adding heat energyto phase change material containers until the phase change material iscompletely liquid and conditioning the liquid phase change material tobe at an acceptable temperature for packaging; or removing heat energyfrom phase change material containers until the phase change material iscompletely solid and conditioning the solid phase change material to beat an acceptable temperature for packaging.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made herein without departing from the spirit andscope of the invention as defined by the appended claims. Moreover, thescope of the present application is not intended to be limited to theparticular embodiments of the process, machine, manufacture, compositionof matter, means, methods and steps described in the specification. Asone of ordinary skill in the art will readily appreciate from thedisclosure of the present invention, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized according to the present invention.Accordingly, the appended claims are intended to include within theirscope such processes, machines, manufacture, compositions of matter,means, methods, or steps.

1. A transport package for a temperature sensitive payload comprising:an outer container; a panel defined by a plurality of interconnectedsegments of phase change material; and a payload section adapted toreceive the temperature sensitive payload, and with the panel beingwrapped around the payload prior to insertion into the outer container.2. The package of claim 1 wherein the panel includes a pair ofintennittently joined film layers defining cavities into which phasechange material is contained.
 3. The package of claim 2 wherein thepanel includes a plurality of voids.
 4. The package of claim 3 whereinthe voids are generally linearly aligned.
 5. The package of claim 1wherein the panel is provided with enhanced flexibility in a directionbeneficial for wrapping the payload.
 6. The package of claim 1 whereinthe panel includes a plurality of segmented sheets.
 7. The package ofclaim 6 wherein said plurality of segmented sheets includes a pair ofsheets, with each of the pair of sheets being thermally preconditioneddifferently than the other prior to wrapping the pair of panels aroundthe payload.
 8. A transport package for a temperature sensitive payloadcomprising: a plurality of segmented panels containing phase changematerial within an interior volume, with said interior volume beingdefined between a pair of fluid impervious layers; and a payload sectionadapted to receive the temperature sensitive payload, and with theplurality of panels being wrapped around the payload prior to insertioninto an outer container.
 9. The package of claim 8 wherein the pair offluid impervious layers are intermittently joined together to define aplurality of volumes containing phase change material.
 10. The packageof claim 9 wherein the pair of fluid impervious layers are joinedtogether via a thermal bonding process.
 11. The package of claim 8wherein at least some of the plurality of segmented panels arepreconditioned differently from each other prior to wrapping thepayload.
 12. A method of packaging a temperature sensitive productcomprising: thermally preconditioning a flexible phase changematerial-containing panel, said panel including a plurality of segmentportions; wrapping the panel around the temperature sensitive product;and inserting the temperature sensitive product wrapped with the panelinto an outer container.
 13. The method of claim 12 flither comprising:sealing the outer container prior to shipment.
 14. The method of claim12 further comprising: thermally preconditioning a second flexible phasechange material-containing panel and wrapping the second flexible phasechange material-containing panel around the temperature sensitiveproduct prior to said insertion.
 15. A method of packaging a temperaturesensitive product comprising: wrapping the payload in a first flexible,segmented panel containing phase change material preconditioned based onan anticipated ambient temperature during transport of the payload;wrapping the payload in a second flexible, segmented panel containingphase change material preconditioned based on another anticipatedambient temperature during said transport; and inserting the payloadwrapped with the segmented panels into an outer container.
 16. Themethod of claim 15 further comprising: wrapping the payload with thermalinsulation prior to said inserting.
 17. The method of claim 15 whereinat least some phase change material has been preconditioned by addingheat energy to phase change material until the phase change material isliquid.
 18. The method of claim 15 wherein at least some phase changematerial has been preconditioned by removing heat energy from phasechange material until the phase change material is solid.
 19. The methodof claim 15 wherein the segmented panels are thermally preconditionedbased on anticipated ambient temperatures during payload transportation.20. The method of claim 15 wherein at least two different thermalpreconditioning processes are used to prepare the segmented panels.